CPE 604_Plant Design and Economic Analysis_Mini Project Report (Production of Phosphoric Acid)_Mohd Wishal PDF

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PLANT DESIGN AND ECONOMICS (CPE 604) MINI PROJECT TITLE: PRODUCTION OF PHOSPHORIC ACID NAME : MINHALINA BATRISYIA BINTI SHAMSHUL BAHARIN (2018262076) : MOHD WISHAL KURNIA BIN MOHD AZMY (2018437792) : WAN SITI AMINAH BINTI WAN NIZU (2018265284) : NUR IZZWA BINTI RAHMAN (2018227032) CLASS : EH220 5G S...

Description

PLANT DESIGN AND ECONOMICS (CPE 604) MINI PROJECT TITLE: PRODUCTION OF PHOSPHORIC ACID NAME

:

MINHALINA BATRISYIA BINTI SHAMSHUL BAHARIN

(2018262076)

:

MOHD WISHAL KURNIA BIN MOHD AZMY

(2018437792)

:

WAN SITI AMINAH BINTI WAN NIZU

(2018265284)

:

NUR IZZWA BINTI RAHMAN

(2018227032)

CLASS

:

EH220 5G

SEMESTER

:

5

SUBMIT TO

:

DR. IR. NORMADYZAH AHMAD

TABLE OF CONTENTS 1.0 PROCESS BACKGROUND .................................................................................................... 6 1.1 Wet Process ........................................................................................................................... 6 1.2 Thermal Process .................................................................................................................... 7 1.3 Dry Kiln................................................................................................................................. 8 2.0 PROCESS SELECTION .......................................................................................................... 9 3.0 SITE SELECTION ................................................................................................................. 11 3.1 Maps for each site selection ................................................................................................ 11 3.2 Site Selection Considerations .............................................................................................. 13 4.0 MARKET ANALYSIS ........................................................................................................... 18 4.1 Global Phosphoric Acid Market-By Application ................................................................ 19 4.2 Global Phosphoric Acid Market-By Region ....................................................................... 23 4.3 Raw Material Market Price ................................................................................................. 25 5.0 MASS BALANCE .................................................................................................................. 26 5.1 Mass Balance....................................................................................................................... 26 5.2 Block Flow Diagram (BFD) ................................................................................................ 27 5.3 Process Flow Diagram ........................................................................................................ 28 5.4 Stream Table ....................................................................................................................... 29 5.5 Mass Balance on Equipment ............................................................................................... 30 5.5.1 Reactor 1 ....................................................................................................................... 30 5.5.2 Filter.............................................................................................................................. 31 5.5.3 Reactor 2 ....................................................................................................................... 32 5.5.4 Separator 1 .................................................................................................................... 33 5.5.5 Separator 2 .................................................................................................................... 34

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5.5.6 Evaporator .................................................................................................................... 35 6.0 PROCESS DESIGN................................................................................................................ 36 6.1 Batch or Continuous ............................................................................................................ 36 6.2 Input and output structure ................................................................................................... 37 6.2.1 Process concept diagram .............................................................................................. 37 6.2.2 Generic block flow diagram ......................................................................................... 38 6.3 The Recycle Structure of the Process .................................................................................. 39 6.3.1 Efficiency of Raw Material Usage ............................................................................... 39 7.0 ENERGY BALANCES .......................................................................................................... 40 7.1 Reactor 1 (R-101) ................................................................................................................ 42 7.2 Filter (V-101) ...................................................................................................................... 50 7.3 Reactor 2 (R-102) ................................................................................................................ 59 7.4 Separator 1 (V-102) ............................................................................................................. 69 7.5 Separator 2 (V-103) ............................................................................................................. 78 7.6 Evaporator (E-101) .............................................................................................................. 84 8.0 HEURISTICS ......................................................................................................................... 90 8.1 Heuristic for Reactor 1 (R-101) .......................................................................................... 90 8.2 Heuristics for Pumps (P-101) .............................................................................................. 93 8.3 Heuristic for separator 2 (V – 103) ..................................................................................... 95 8.4 Heuristic for Evaporator (E – 101) ...................................................................................... 98 9.0 ECONOMIC ANALYSIS .................................................................................................... 101 9.1 Equipment Costing ............................................................................................................ 106 9.1.1 Reactor 1 (R-101) ....................................................................................................... 106 9.1.2 Pump (P-101).............................................................................................................. 107 9.1.3 Evaporator (E-101) (Falling Film Evaporator) ........................................................... 110

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9.2 Summary of Bare Module Cost of Equipment’s ............................................................... 112 9.3 Total Module Cost, and Fixed Capital Investment ........................................................... 113 9.4 Raw Material Cost ............................................................................................................. 114 9.5 Cost of Operating Labour .................................................................................................. 115 9.6 Estimating Cost of Manufacturing .................................................................................... 116 9.6.1 Direct Manufacturing Cost ......................................................................................... 116 9.6.2 Fixed Manufacturing Cost .......................................................................................... 117 9.6.3 General Manufacturing Cost ...................................................................................... 117 9.6.3 Discounted Cash Flow (Manually Calculated) ........................................................... 118 10.0 PROFITABILITY ANALYSIS .......................................................................................... 119 10.1 Equipment Summary (CAPCOST) ................................................................................. 119 10.2 Raw Material and Product Cost (CAPCOST) ................................................................. 120 10.3 Cost of Manufacturing Summary (CAPCOST) .............................................................. 121 10.4 Cash Flow Diagram for Discounted (CAPCOST) .......................................................... 122 10.5 Cash Flow Diagram for Non-Discounted (CAPCOST) .................................................. 123 10.6 Cash Flow Analysis (CAPCOST) ................................................................................... 124 11.0 REFERENCES ................................................................................................................... 125 12.0 APPENDIX ......................................................................................................................... 128 12.1 Material Safety Data Sheet .............................................................................................. 128 12.1.1 Sulphuric Acid .......................................................................................................... 128 12.1.2 Water ........................................................................................................................ 135 12.1.3 Phosphoric Acid ....................................................................................................... 139 12.1.4 Gypsum ..................................................................................................................... 143 12.1.5 Hydrofluoric Acid..................................................................................................... 149 12.1.6 Calcium Phosphate ................................................................................................... 156

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1.0 PROCESS BACKGROUND Phosphoric acid, also known as orthophosphoric acid (H3PO4), the most significant phosphorus oxygen acid, was used to create fertilizer phosphate salts. It is also used in dental cements, albumin derivatives preparation, as well as in the sugar and textile sectors. It serves in food products as an acidic, fruit-like taste (britannica). In industry nowadays, the production of Phosphoric Acid was produced mainly from three routes, which are wet process, thermal process and dry kiln. Each of this method produced a different grade of phosphoric acid to be used in the industry for further process and specified product functionality.

1.1 Wet Process Wet process is the most common ways of producing phosphoric acid (Guichon valves, n.d.). Phosphoric acid is produce using fluorapatite, which is the phosphate rock, 3Ca3(PO4)2. CaF2 and concentrated (93%) sulphuric acid as the raw materials (The Essential Chemical Industry, 2017). Phosphoric acid produced by this process usually used to make phosphate fertilizers such as

Mono-Ammonium

Phosphate

(MAP),

Di-Ammonium

Phosphate

(DAP),

Triple

Superphosphate (TSP) and Single Superphosphates (International Fertilizer Association, 2019) This is because, the wet process usually produced phosphoric acid with lower purity as low as 45% purity (Guichon valves, n.d.). Sulphuric acid and phosphate rock are fed to the reactors producing a low purity phosphoric acid that contain small percentage of solid, calcium phosphate and calcium sulphate (gypsum). The generated calcium phosphate will be recycled back to the reactor in order for it to undergo reaction with sulphuric acid to produce phosphoric acid. Filtration process will separate gypsum from the phosphoric acid. Next, the separated phosphoric acid was fed to a settling tank (Inorganic Chemical Industry, 1995). A portion of the acid that contain solid phosphate rock were recycled back to the reactor. The remaining phosphoric acid are sent to the evaporator to increase the product purity from 26% purity to 45% purity of phosphoric acid.

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The produced phosphoric acid also can become intermediate product in the manufacturing of wide variety of fertilizers and other chemical products. 85% of produced phosphoric acid mostly used to make fertilizers. In example, reaction between phosphoric acid and ammonia will produced monoammonium phosphate (MAP) and di-ammonium phosphate (DAP). While reacting phosphoric acid with phosphate rock will produce triple superphosphate (TSP) (International Fertilizer Association, 2019)

1.2 Thermal Process Raw materials for phosphoric acid production by the thermal process are elemental phosphorus, air, and water. Thermal process of producing phosphoric acid involves 3 major steps which are combustion, hydration, and demisting (Inorganic Chemical Industry, 1995). At combustion stage, the elemental phosphorus in liquid form is oxidized in ambient air by burn it in a combustion chamber at a very high temperatures to form phosphorus pentoxide. Next is hydration process. The phosphorus pentoxide produced by combustion is then hydrated with dilute phosphoric acid or water to produce strong phosphoric acid liquid. Last process is demisting that were done using a high-pressure drop demister. It will remove the phosphoric acid mist from the combustion gas stream before release to the atmosphere (Inorganic Chemical Industry, 1995). Concentration of phosphoric acid produced from thermal process normally in the range of 75 to 85 %. Thermal process production of phosphoric acid usually uses food industries because the product has a higher chemical grade (Guichon valves, n.d.).

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1.3 Dry Kiln For dry kiln process, it is an improved process from thermal process. For thermal process, it used electrical arc furnace to burn the phosphorus. But for the improved method, it used rotary kiln which also known as dry kiln to burn the phosphorus using direct-fired to the reactor (Shaw, 2002). The burning of phosphorus will further be produced carbon monoxide as co-product and will continued to be burnt out throughout the process continuously. This reaction will generate heat of combustion which most of it will be used to replace the electrical energy that usually used in conventional method. By using heat of combustion to generate energy, this method had proved that it would be much energy saving than the conventional thermal process. Although this process had shown much improvement and better impacts to the environment, but this process currently conducted in pilot plant scale (Shaw, 2002). Research for this method is still on going to be expand to industrial scale, which could affect the energy, cost saving and reducing its carbon footprint itself to the environment.

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2.0 PROCESS SELECTION Table 1: The assigned value used for screening method and the meaning of the assigned value Assigned values

Meaning

-

Worse than

0

Same as

+

Better than

Table 2: Screening Method for Process Selection Criteria

Wet Process

Thermal process

Dry Kiln Process

Raw Material

+

+

+

By-product

0

0

0

Purity

+

+

+

Production scale

+

+

-

Cost

+

0

0

Total Score

4

3

1

Ranking

1

2

3

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Table 3: The assigned value used for scoring method and the meaning of the assigned value Assigned values

Meaning

1

Much worse than reference

2

Worse than reference

3

Same as reference

4

Better than reference

5

Much better than reference

Table 4: Scoring Method for Process Selection Criteria

Weight

Wet Process

Thermal process

Dry Kiln Process

Raw Material

30%

5

4

4

By-product

5%

3

3

3

Purity

30%

4

5

5

Production scale

15%

5

5

2

Cost

20%

5

3

3

Total Score

100%

4.6

4.2

3.75

1

2

3

Ranking

From the screening and scoring method for the process selection, it has been decided for Phosphoric Acid production will be using wet process as our process as it has many advantages compared to the other process.

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3.0 SITE SELECTION Three places were recognized and suggested for the site location method for the new project organization. Kemaman in Terengganu, Bintulu in Sarawak and Senai in Johor Bharu were the place that had already been narrowing down.

3.1 Maps for each site selection Kemaman, Terengganu

Figure 1: Site location that have been chosen on Kemaman, Terengganu

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Bintulu, Sarawak

Figure 2: Site location that have been chosen on Bintulu, Sarawak Senai, Johor

Figure 3: Site location that have been chosen on Senai, Johor 12 | P a g e Phosphoric Acid Production

3.2 Site Selection Considerations 1. Raw Material Availability Before choosing a site location, it is important to make research whether the area had supplier for the raw material as nearest as possible as this would save cost in term of transportation, shipping and also time saving.

2. Market Availability For our products to easier purchase by customer, it is vital to choose a location that is near to potential customer so that it can be advantages to customer that could save cost of transportation, and time required for shipping.

3. Availability of labour Labour supply is important and crucial for a plant to run smoothly and efficiently. It is needed for construction and its operation. Thus, the location must be available for labour supply otherwise the production of the plant will be interrupted and could lead to loss of the chemical plant itself.

4. Transportation Transportations includes the existing railroads, highways that were common to be used by industrial itself. By having an easier transportation, it could save a lot of cost, time and energy saving. The proximity to railroad and the possibility of ocean transport must be considered.

5. Utilities Utilities is also a critical part of the plant. Choosing a site location with availabilities to provide utilities such as electricity to the plant is important to ensure that the plant to run. The main electricity power generator in Malaysia is Tenaga National Berhad (TNB) and for Sarawak it is Sarawak Energy Berhad (SEB).

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6. Climate It is necessary to consider the extreme situation of a location as excessive humidity or extremes of hot or cold weather will cause a need for the plant to have trigger effect on the plant equipment.

7. Land estimation Land topography must also be taken into account as it will i...